Influence of Pin Temperature on Dry Sliding Wear Behaviour of Ni–Al2O3 Composite Coating on Al6061 Substrate

The lightweight materials like aluminium is used in most of the automobile, aeronautical applications due to its high strength to weight ratio. In the present study, high-temperature wear behaviour of Al6061 substrate material with Ni–Al2O3 nanocomposite coating at different elevated temperatures is studied. The tests were conducted at dry sliding wear conditions. The coating was carried out by electrodeposition process. In addition to high-temperature specific wear, hardness of the glaze layer and friction force of composite coating are investigated. The results reveal that the dominant wear mechanism of the Ni–Al2O3 coating was in abrasive nature at 40 °C which turned into completely adhesive nature at elevated temperatures between 80 and 140 °C. The minimum mild wear with reduced frictional force was noticed at 80 °C due to the formation of glaze layer. This anti-wear resistance glaze layer is formed by the sintering of debris and oxide particles at the interface of pin and disc. At 140 °C, severe wear with serious plastic deformation was observed. The improvement in the specific wear is attributed by the presence of nano-Al2O3 particles in the Ni matrix and wear resistant glaze layer. This was witnessed by the microstructure observations by SEM, EDS, and microhardness measurements. © 2020, The Institution of Engineers (India).